AW60-40LE-ZIP-IN.pdf

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PART NUMBERAW60-40LE-ZIP QUICK GUIDE

2012 Sonnax Industries, Inc. AW60-40LE-ZIP-Guide 09-26-12

800-843-2600 802-463-9722 F: 802-463-4059 www.sonnax.com Page 1

AISIN AW 60-40LE (AF-13)ZIP KIT

Parts are labeled here in order of installation. See other side of sheet for details on Zip Kit contents.

In addition to general rebuilding tips and technical information, the technical booklet included in this kit contains vacuum testing

and additional repair options for higher mileage units or for repairing specic complaints which are beyond the scope of this kit.

60-40LE (AF-13) Valve Body

NoNumber 2

Rear Control

Body

Has a

Short TCC

Solenoid

Valve Body Identification NOTE:This Zip KitAW60-40LE-ZIPis designed for 60-40LE (AF-13) applications only.A separate Zip KitAW60-41SN-ZIPis available for 60-41SN (AF-17) applications.

Checkballs

10 Small

1 Large

Front ControlValve Body

Rear Control Valve Body

Has aNumber 2

Rear Control

Body

60-41SN (AF-17) Valve Body

Has a

Long TCC

Solenoid

Lowest of three OE

sleeve steps.Check which step the retainer location sleeveis on, to determine how many shims (if any) arerequired for Sonnax replacement assembly.

OE Assembly Shown

ShimLocation


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Aisin AW 60-40LE ZIP KIT Quick Guide

2012 Sonnax Industries, Inc. AW60-40LE-ZIP-Guide 09-26-12


Step Replace OE Boost

Assembly

Observe the step location of the retainer on OE sleeve prior to removal.

If set at the lowest step, do not use the Sonnax shims. If set at middle

step, use one Sonnax shim. If set at the highest step, use two Sonnax

shims. Shims should be place on inboard sleeve diameter.

Boost Valve & Sleeve Kit

Packaging Pocket 1

Valve Sleeve Shims (3) 1 extra

Step Replace OE Accumulator

Control Valve AssemblyAccumulator Control Valve & Sleeve Kit

Packaging Pocket 2

Valve Sleeve

Step Replace OE B1 Modulator

Valve Assembly

Discard OE retainer and use replacement pin to retain lineup.

B1 Modulator Valve & Sleeve Kit

Packaging Pocket 3

Valve Sleeve Retaining Pin

Step Replace OE End Plugs

1-2 & 2-3 Shift Valve O-Ringed End Plug Kit

Packaging Pocket 4

End Plugs, Medium (2) O-Rings, Medium (4) 2 extra

Step Replace OE End Plug

3-4 Shift Valve O-Ringed End Plug Kit

Packaging Pocket 5

End Plug, Large O-Rings, Large (2) 1 extra

Step Replace OE Solenoid

O-Rings

Solenoid O-Rings

Packaging Pocket 6

O-Rings, Small (4) 1 extra

Step Replace OE TCC Control

Assembly

TCC Control Valve Kit

Packaging Pocket 7

Valve Sleeve

Step Replace OE Secondary

Regulator Valve End Plug

Secondary Regulator Valve O-Ringed End Plug Kit

Packaging Pocket 8

End Plug, Large O-Rings, Large (2) 1 extra

Step Replace OE Checkballs

Checkballs

Packaging Pocket 9

Checkballs, Small .218" dia. (10) Checkball, Large .250" dia.

Zip Kit Contents & Installation Steps


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NOTE:This Zip KitAW60-40LE-ZIPis designed for 60-40LE (AF-13) applications only.

A separate Zip KitAW60-41SN-ZIPis available for 60-41SN (AF-17) applications.

Valve Body Identification60-40LE (AF-13) Valve Body: Use this kit.

60-41SN (AF-17) Valve Body: Use AW60-41SN-ZIP kit.

Torque SpecificationsTransaxle SideCover Bolt

18 ft-lb

Manual DetentSpring Bolt

90 in-lb

Manual Shift Lever Nut

60 in-lb

Front Valve BodyCover Bolt

18 ft-lb

Front-Valve-Body-to-Rear-Valve-Body Bolt

60 in-lb

Rear Valve BodyCover Bolt

96 in-lb

Solenoid-to-Valve-Body Bolt

60 in-lb

Valve-Body-to-Transaxle Bolt

90 in-lb

Fluid ChartRecommended Capacities: Dexron-III ATF

Approximate Capacity,Complete Overhaul

6.0 qt (5.7L) - 1.6L6.2 qt (5.9L) - 1.8L

Approximate Capacity,

Drain and Fill

2.9 qt (2.7L) - 1.6L2.9 qt (2.7L) - 1.8L

Has aNumber 2

Rear ControlBody

60-41SN (AF-17) Valve Body 60-41SN (AF-17) Valve Body

Has aLong TCCSolenoid


Has aShort TCCSolenoid


NoNumber 2

Rear ControlBody

Component Apply Chart

PositionClutch Brake 1-Way Clutch

Forward Coast Reverse OD 1st-Reverse 2nd-4th No. 1 No. 0

P X

R X X X

N X

D

1 X X X X

2 X X X X

3 X X X X

4 X X X

21 X X X X

2 X X X X

L 1 X X X X X

AISIN AW 60-40LE (AF-13)ZIP KIT

PART NUMBERAW60-40LE-ZIP INSTALLATION & TESTING BOOKLET

2014 Sonnax Industries, Inc. AW60-40LE-ZIP-Booklet.indd 01-31-1

800-843-2600 802-463-9722 F: 802-463-4059 www.sonnax.com Page


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Aisin AW 60-40LE ZIP KIT Installation & Testing Booklet

01-31-14 AW60-40LE-ZIP-Booklet.indd 2014 Sonnax Industries, Inc

Page 2 800-843-2600 802-463-9722 F: 802-463-4059 www.sonnax.com

TIME TESTED INDUSTRY TRUSTED

SolenoidsTis 60-40LE unit uses four solenoids (Figure 1).

he S1 (shift solenoid no. 1) and S2 (shiftsolenoid no. 2) are an on/off style, operated bythe CM to control the various shifts. hese two

solenoids are interchangeable.

he CC control solenoid is an on/off stylecontrolled by the CM to operate the converterclutch.

he throttle pressure control liner solenoid ismodulated by the CM to regulate line pressure.

Zip Kit Instructions

1. Valve Body DisassemblyNOTE:See color charts for bolt lengths.

a. Remove the 13 bolts (Figure 2).

b. Remove the small cover, CC control solenoid,throttle pressure control solenoid (Figure 1) andbrackets.

c. Remove the two bolts (Figure 3), two shift sole-noids (Figure 1) and front valve body cover,separator plate and gasket.

d. Remove the three checkballs, two oil filters, one

check valve and spring, four bolts and one brack-et (Figure 4).

Figure 1

TCC Solenoid1115 ohm

Test all four solenoids at20C/68F.

Throttle PressureControl Solenoid

35 ohm

Shift Solenoids(interchangeable)

1115 ohm

No. 1

No. 2

Figure 2

Bolt installation torque specifications are 60 in-lb.

Figure 3

Bolt installation torque specifications are 60 in-lb.

Bolt ColorCode

BoltLength

Yellow 10mm

Red 16mm

Orange 20mm

Green 38mm

Blue 50mm

Solenoid Apply Chart

PositionSolenoid

No. 1 No. 2 TCC

P X

R X

N X

D

1 X

2 X X

3 X X1

4 X1

21 X

2 X X

L 1 X

1On only when TCC is operating.


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1. Valve Body Disassembly

(continued)

e. Flip valve body over and remove five bolts. Liftrear valve body and separator plate off of frontvalve body (Figure 5).

f. Remove 11 bolts to access valves retained underthe two rear valve body covers (Figure 6).

2. Installation

Install Zip Kit parts as shown on diagram ofseparate quick guide sheet included in this Zip Kit.

3. Valve Body Assembly

a. Reinstall the two rear valve body covers andloosely install the 11 bolts (Figure 6), then torqueto 96 in-lb.

b. Reinstall the separator plate, gasket and rear valvebody onto the front valve body (first ensuring allcheckballs, check valves and filters are in properlocations). Loosely install the five bolts (Figure 5),then torque to 60 in-lb.

c. Flip the valve body over.

d. Loosely install the four bolts (Figure 4), andtorque the four bolts to 60 in-lb.

e. Place the front valve body cover, gasket andseparator plate onto the front valve body.Reinstall the two shift solenoids and looselyinstall the two bolts (Figure 3).

f. Reinstall the brackets, throttle pressure control

solenoid, CC control solenoid (Figure 1) andsmall cover.

g. Loosely install the 13 bolts (Figure 2) and thentorque all 15 bolts to 60 in-lb.

Figure 4

Bolt installationtorque specifications

are 60 in-lb.

Figure 5


are 60 in-lb.

Figure 6


are 96 in-lb.

Bolt ColorCode

BoltLength

Yellow 10mm

Red 16mm

Orange 20mm

Green 38mm

Blue 50mm


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Critical Wear Areas & Vacuum Test LocationsNOTE:OE valves are shown in rest position and should be tested in rest position unless otherwise indicated. Test locations are pointed to with an arrowSprings are not shown for visual clarity. Low vacuum reading indicates wear.

Front Control Valve Body - Separator Plate Side Shown Here

2nd/4th Brake ModulatorPlunger Assembly

Shift complaints in 2nd & 4th 2-3 Shift Valve2-3 Shift complaintsNOTE: Seal port on opposite side ofcasting & solenoid port with thumb.

2nd/4th BrakeModulator ValveShift complaints in 2nd & 4th

1-2 Shift Valve

1-2 Shift complaintsNOTE:Seal port on opposite side of casting.

Pressure Regulator Valve

Low/High line pressure

Soft/Harsh shifts

Converter complaints

Loss of lube


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Front Control Valve Body - Cover Side Shown Here

20

25

15

0

10

5

30

VACUUM

TEST

1-2 Shift Valve

1-2 Shift complaintsNOTE: Seal port on opposite side of casting.

3-4 Shift Valve

3-4 Shift complaints

Pressure Regulator Valve

Low/High line pressure

Soft/Harsh shifts

Converter complaints

Loss of lube

Shift Valve End PlugsShift complaints

Reverse BoostAssembly Low reverse pressure

Delayed reverse

TCC Modulator Valve

Converter slip/shudder/codes

No converter applyNOTE:Test using non-orificed 2nd/4thmodulator brake control valve.

Seal

Seal

2-3 Shift Valve

2-3 Shift complaintsNOTE:Seal port on opposite side of casting andseal solenoid port with thumb.

3-4 Shift Valve3-4 Shift complaintsNOTE: Seal solenoid port with thumb.


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Critical Wear Areas & Vacuum Test LocationsNOTE:OE valves are shown in rest position and should be tested in rest position unless otherwise indicated. Test locations are pointedto with an arrow. Springs are not shown for visual clarity. Low vacuum reading indicates wear.

Rear Control Valve Body- Separator Plate Side Shown Here

20

25

15

0

10

5

30

VACUUM

TEST

Secondary Regulator Valve TCC complaints

Loss of lube

2nd/4th Brake ModulatorControl Valve

Burned 2-4 brake

Shift complaints in 2nd & 4th

2-3 Timing Valve& Overdrive ClutchAccumulator Piston

2-3 Shift complaints

Burned overdrive clutch

Bump in 3rd gearNOTE: Test one port while sealing the other.

2nd/4th Brake

& Foward ClutchAccumulator Piston Burned forward clutch

Burned 2-4 brake

Delayed forward

Bump 2nd & 4th gear

Reverse ClutchAccumulator Piston Burned reverse clutch

Delayed reverse

Bump in reverse

Solenoid Modulator ValveShift complaintsNOTE:Test using non-orificed 2nd/4th brakemodulator control valve

Coast ClutchModulator ValveBurned coast clutchNOTE:Test using non-orificed 2nd/4thbrake modulator control valve.

TCC Control Valve

Lockup complaints/codes

Low CoastModulator Valve Burned 1st & reverse clutch

Delayed engagement reverseor 1st in manual low

NOTE:Test both at the same time.


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OE Exploded ViewFront Control Valve Body - Cover Side (Separator Side Inset) Shown Here

Front Control Valve Body Descriptions

I.D. No. Description

101Reverse Boost Assembly& Pressure Regulator Valve

102Accumulator Control Valve& Plunger Assembly

1032nd/4th Brake Modulator Valve& Plunger Assembly

104 1-2 Shift Valve

105 2-3 Shift Valve

106 3-4 Shift Valve107 TCC Modulator Valve

Front Valve Body(Cover Side)

107

102

101

103

Filter

106

105104

CheckValve

Front Control Valve Body(Separator Side)

Check Valve

Filter


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Rear Control Valve Body Descriptions

I.D. No. Description201 Secondary Regulator Valve

2022nd/4th Brake ModulatorControl Valve

203 Low Coast Modulator Valve

204 Solenoid Modulator Valve

205Reverse Clutch

Accumulator Piston

2062nd/4th Brake

Accumulator Piston

207 Manual Valve

208 Forward ClutchAccumulator Piston

209Overdrive Clutch

Accumulator Piston

210 2-3 Timing Valve

211 Coast Clutch Modulator Valve

212TCC Control Valve& Plunger Assembly

207

Filter

212

208 209

210

211

206

205

204

203

202

201

CheckValve

ChecValve

CheckValveCheckball, Large .250" dia.

(All 10 others, Small .218" dia.)

OE Exploded ViewRear Control Valve Body

AW60-40LE-ZIP-IN.pdf

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